charging system woahs

[jdub]

Expert advice needed on a regulator issue ive been having. My regulator was bad so i replaced it with a new one from ebay from celox. First one i hooked up, smoked and burnt up when the key was turned on, second one i tested, but have not hooked up yet. My concern is, it fails the factory testing as the brown wire (switched ignition) has good voltage from the bike, but the regulator grounds to earth both ways on the brown wire like there is no diode on it. If i hook it up, my gut says this one will burn up too. Any ideas? I thought maybe the green and brown wires on the regulator may be backward? I dont have a factory one to compare it to, so i was hoping someone else has had a problem like this...

[cajun31]

Been waiting

to see if some of the electrical gurus were going to chime in for you. They probably still will just give it some time. In the meantime what I would do if I were having the problem you have described is check or double check all wiring connections on the bike period including grounds. Get some dielectric grease and coat all of the connections as you work your way through. I would also inspect our starter switch on the handle bar as well as the ignition switch. It looks to me like you have a direct short somewhere. Just my 2 cents.

[BA80]

Not an electrickery guru but it seems you have a dead short somewhere BEFORE the fuses. It should blow a fuse, not a regulator.

[jdub]

Thanks for the response. I have cleaned all connections and cleaned the ignition switch, greased all connectors and ohm tested the stator and field coil. The stator does ohm a bit out of spec at .9 ohms but no grounding. I have not yet had the time to pull the stator/field coil, but i am just baffled the brown wire on both regulators ground through the reg/rect. This cant be right can it? Maybe one way with a diode?

[jdub]

It did blow the main fuse , first one blew once, replaced it , then it smoked on the second fuse. The replacement regulator, i finally tried, blew the fuse but did not hurt the reg/rect.

[BA80]

I would unplug the two connectors that go to the alternator and see what happens.

Be prepared to pull the plug to the regulator as soon as you plug it in so you don't kill another one.

[BA80]

Most likely there is a dead short in the alternator stator or coil.

[TopCatGr58]

Hey Jdub,

Another member recently posted about a replacement Reg/Rect he got, and as soon as he turned the key on, it would blow the fuse. Upon looking at it from his posts, we postulated that 2 of the wires were routed backwards in the plug, I can't remember which plug. I'll do a search for the thread and post the link to it.

T.C.

[jdub]

Thats what i was thinking too topcat, i did try the brown and green reversed, but popped the fuse again. Checked the stator and field coil after to make sure no damage was done.

[jdub]

The only other two that may do anything would be the black and red...

[TopCatGr58]

Hey again,

Yep, it was the Red/Black ones, here's the thread, photos are still there.

http://www.xs11.com/forum/showthread...ight=regulator

However, the original poster never posted a followup to the problem, so don't know if he solved it, or if he returned it to the seller????

[jdub]

Connector wire colors are right, but i think they are still wired backwards. I will check it out tomorrow and post results.. need to get some main fuses tomorrow.

[jdub]

Well, the wires ohm the same as the old rectifer, but the regulator is burnt up in my old one. Does anyone have testing results from the black wire to the brown one on a known good regulator ? Mine does ohm both ways at around .948 ohms. I dont think this is right as the brown wire is switched ignition.

[bikerphil]

I tested 2 regulators today that are supposed to be good, and between the brown and black wires I got 2.57KΩ on the first one and 2.03KΩ on the second, HTH.

Edit: this test is between the brown field coil wire and the black (ground?) in the 6 pin plug, some units have a 3rd wire (black) in the field coil plug, both tested didn't have that.

[jdub]

Thanks bikerphil for testing those for me. Not the news i wanted to hear, But it points me in a better direction now. I guess its back to searching wires and possibly a stator and field coil change. I may be riding this year yet. lol